1988 FIAT TEMPRA maintenance

Please read the whole of the Introduction to this Chapter before carrying out any work on your car.
CHAPTER 5
SERVICING YOUR CAR
Everyone wants to own a
car that starts first time,
runs reliably and lasts
longer than the average.
And it's all a question of
thorough maintenance!
If you follow the FIAT-
approved Service Jobs
listed here you can almost
guarantee that your car will
still be going strong when
others have fallen by the
wayside
-
or the hard
shoulder.
How To Use This Chapter
This chapter contains all of the servicing Jobs recommended
by FIAT for all models of Tipo and Tempra imported into the
UK except cars with 1.8 and 2 litre DOHC petrol engines. To
use the schedule, note that:
• Each letter code tells you the Service Interval at which you
should carry out each Service Job.
• Each Service Job has a Job number.
• Look up the number in the relevant part of this chapter and
you will see a complete explanation of the work.
SAFETY FIRST!
SAFETY FIRST information must always be read with
care and always taken seriously.
• In addition, please read the whole of Chapter 1,
Safety First! before carrying out any work on your
car.
• There are many hazards associated with working on
a car but all of them can be avoided by adhering
strictly to the safety rules.
• Don't skimp on safety!
SERVICE INTERVALS - INTRODUCTION
• We think it is very
important to keep things as
straightforward as possible.
And where you see this heading, you'll know there's
an extra tip to help 'make it easy' for you!
Over the years, FIAT, in common with all other manufacturers,
have lengthened their recommended service intervals. For
instance, oil changes on later FIATs don't have to take place as
often as earlier ones. In the main, these changes have not
come about because of specific modifications to the cars
themselves. They have come about because of a number of
factors: Lubricants, spark plugs, seals and other components
have improved and mechanical parts are better made due to
improved materials and production techniques.
As a result, you are recommended to follow the maker's
recommendations on how often to service your car. If your car
lies right on a change-over point, the choice of which
schedule to follow will be yours, unless the specific advice
given here recommends otherwise
-
as we said earlier, most
change points came about for a number of reasons, so it
generally isn't necessary to identify with pinpoint accuracy
which bracket your car belongs to, if it isn't obvious.
32

(ignition-ON) position and press down the button between the
two terminals on the reservoir cap
-
when fitted. The warning
light on the dash should light up. When no button is fitted,
unscrew and raise the cap (ignition key ON) to check the
warning light. Check the bulb, check the fuse, or have your
FIAT dealer repair the warning system, if faulty.
• Job 4. Battery
-
check electrolyte level.
FACT FILE: DISCONNECTING THE
BATTERY
• Many vehicles depend on a constant
power supply from the battery; with
these you find yourself in trouble if you
simply disconnect the battery. You
might find the car alarm goes off, or that the engine
management system forgets all it ever 'learned', making
the car feel odd to drive until it has re-programmed
itself. You might also find that the radio refuses to
operate until its correct security code is keyed into it.
• On cars with engine management systems and/or
coded radios, you must ensure the car has a constant
electrical supply, even with the battery removed. You
will need a separate 12 volt battery; put a self-tapping
screw into the positive lead near the battery terminal
before disconnecting it, and put a positive connection
to your other battery via this screw.
• Be EXTREMELY CAREFUL to wrap insulation tape
around the connection so that no short is caused. The
negative terminal on the other battery must be
connected to the car's bodywork.
SAFETY FIRST!
• The gas given off by a battery is highly explosive.
Never smoke, use a naked flame or allow a spark in
the battery compartment.
• Never disconnect the battery (it can cause sparking)
with the battery caps removed.
• All vehicle batteries contain sulphuric acid. If the
acid comes into contact with the skin or eyes, wash
immediately with copious amounts of cold water and
seek medjcal advice.
• Do not check the battery levels within half an hour
of the battery being charged with a separate battery
charger because the addition of fresh water could
cause electrolyte to flood out.
4. Check the electrolyte
level in the battery. MAX
and MIN lines (arrowed)
are moulded into the
translucent battery
casing. In the case of
non-FIAT-supplied
batteries, the cell caps or
strip (a) may need to be
removed to see the level.
Original FIAT batteries are of the 'maintenance-free' type and
usually do not need topping-up. However, if necessary, top up
after prising off the cell sealing strip with a screwdriver. Top-
up each cell ONLY with distilled or de-ionised water.
• Job 5. Screen/headlight washer fluid
check level.
5A. Top up with a mixture of
water and screen-wash
additive, mixed according to
the instructions on the
container. FIAT recommend
Arexons DP1. The reservoir
for front screen, rear screen
and headlights (as appro-
priate) is situated in the engine
bay: adjacent to the left-hand
strut, behind the battery...
5B. ...and behind the
coolant expansion
tank on diesel
models, as illustrated
here.
• Job 6. Tyres
-
check pressures and condition
(road wheels).
/
6A. Check the tyre
pressures using a
reliable and accurate
gauge. Note that the
recommended
pressures (see
Chapter
3,
Facts and
Figures) are given for ^^
iH^KKSEI ^ "'

COLD tyres. Tyres
warm up as the car is used
-
and warm tyres give a false (high)
reading. You should also check for wear or damage at the
same time.
SAFETY FIRST!
• If a tyre is worn more on one side than another,
consult your FIAT dealer or a tyre specialist. It probably
means the tracking needs re-setting, though it could
indicate suspension damage, so have it checked.
• If a tyre is worn more in the centre or on the edges,
this indicates incorrect tyre pressures.
• Incorrectly inflated tyres wear rapidly, can give
dangerous handling, and can worsen fuel
consumption.
Every three months,
raise each wheel off
the ground and turn it
slowly between your
36
6B. Every few weeks, examine the tyre treads for wear using a
tread-depth gauge. This will help you keep safe and on the
right side of the law!
Check treads visually
every time you check
the pressures.

Job 2. Ignition coil - replacement.
ALL 1.4 MODELS AND 1.6 MODELS UP TO 1993
Q Step 1: Locate the coil (2) next to
the battery.
IMPORTANT NOTE: On 1.6 models
from 1993 with SPI Monomotronic
fuel injection, the high tension coil
is integral with the distributor.
• Step 2: Make sure the ignition is
switched off and disconnect all LT (the
smaller, low tension) wires from the
coil, making note of their locations for
refitting.
• Step 3: Unplug the HT (the
thicker, high tension) lead to the
distributor at the coil end. Undo the
mountings and remove the coil.
• Step 4: Mount the new coil, remake all connections
correctly and firmly.
Job 3. Distributor - removal and
refitting (1.4 litre engine).
FACT FILE: 1.4. LITRE ENGINE
DISTRIBUTOR
This system is of the BREAKERLESS
INDUCTIVE DISCHARGE type (2nd gener-
ation) and employs a distributor looking
much like those used on older cars, still
having an internal centrifugal advance mechanism, a vacuum
advance mechanism (3),
but NO contact breaker
points - an electronic
control module (2)
instead. This means that
once set, the timing
cannot alter through
points gap fluctuation.
Maintenance is also
reduced to a minimum,
the main requirements
being to keep the unit
clean and dry.
l_) Step 1: Locate the distributor (see illustration Job1-2A,
part a) which is mounted on the forward facing side of the
engine block, close to the timing belt cover.
I—] Step 2: Remove the distributor cap and leads.
Q Step 3: Disconnect the (thinner) low tension lead, undo
the distributor base clamp and withdraw the distributor.
Q Step 4: Turn
the engine until
the crankshaft
pulley timing
mark is aligned
with the '0' (TDC)
mark on the
timing belt cover
(a) and the marks
seen through the
timing belt
window (b), also
line up.
• Step S: If the
marks

seen through the window
do not align
-
turn the
engine another complete revolution and they will.
• Step 6: Refit the distributor with the centre of the rotor
contact pointing 180 degrees away from (in other words,
exactly opposite) the reference mark on the distributor dust
cover.
Q Step 7: Refit the distributor cap and remake all connec-
tions. Leave the vacuum pipe disconnected but plug the end
of the pipe.
Q Step 8: Refit the base clamp but leave just loose enough
to allow the distributor to turn.
Q Step 9: Connect a stroboscopic timing light and start the
engine. Run it at between 750 and 850 rpm.
• Step 10:
Rotate the
distributor body
the required
amount in either
direction to align
the pulley timing
mark with the 10
degree BTDC
mark on the
timing belt cover
• Step 11: Remove the timing light, unplug and reconnect
the vacuum pipe.
Job 4. Distributor - removal and
refitting (1.6 litre engine).
FACT FILE: 1.6 LITRE ENGINE
DISTRIBUTOR
The DIGIPLEX 2 ALL ELECTRONIC (2nd
generation) IGNITION system used on the
1.6 litre engine is of advanced design and
requires no maintenance. Because there is no
mechanical wear, the advance curves remain constant during
the life of the unit. Inaccuracies due to wear or vibration are
eliminated. The high spark intensity is constant, even with a
low battery when starting, and at high RPM.
and lock the distributor base clamp.

Job 14. Exhaust system -
replacement.
FACT FILE: LAMBDA SENSOR
• The Lambda sensor is very fragile and
should not be knocked or dropped.
• We recommend that a new one is fitted
only by your FIAT dealer, who can test the
old one to see whether it is working properly.
• No cleaners should be used on the sensor.
Q Step 3: Before refitting, check that the sensor sealing ring
is in good condition, and lubricate the thread of the sensor
with a high-temperature anti-seize compound.
Job 13. Fuel evaporation system.
a - fuel tank b - two way safety valve c - multi purpose valve d
-
active charcoal filter e - petrol vapour cut out valve
f - electronic control unit g - crankcase blow by pick up h - thermostatic air filter vacuum pick up i - fuel filter
• Point 1: A complex control system exists to prevent
evaporative losses of fuel vapour to the atmosphere, and to
control fuel tank pressure under different temperature condi-
tions.
—) Step 1: Exhaust systems are similar in principle
-
and
mostly in appearance
-
between engine types but differ in that
some have a Lambda sensor, and a catalytic converter. This is
a typical system.
• Step 2: If a Lambda sensor is fitted, see Job
12
for
important information regarding removal.
• Step 3: Undo the downpipe to manifold flange bolts.
• Step 4: With a helper to support the weight, release the
exhaust system from its mountings along its length and lower
it to the ground.
O Step 5: Separate the sections if only part of the system is
being replaced. Take care not to damage the catalytic
converter if this is staying.
• Step 6: Refit by starting at the front and fitting the down
pipe using a new gasket, just nipping up the flange bolts.
• Step 7: Continue fitting loosely towards the rear until all
is in place, using new gaskets and sealing compound, as
required, for each of the joints.
• Step 8: Working from the front, align the system, tight-
ening each flange or joint as you go.
• Step 9: Reconnect the Lambda sensor if fitted.
• Point 2: The system comprises a charcoal canister which
absorbs fuel vapour from the fuel tank, mostly while the
vehicle is standing, then re-injects it when the engine is
running. The valves which regulate the system are controlled
by the engine's electronic control unit.
• Point 3: Other than occasional replacement of the
charcoal canister, no system maintenance is needed. However,
a fault with the system can lead to running problems, and
diagnosis and rectification must be left to your FIAT dealer.
Job 15. Tlurbocharger, diesel
engine - replacement.
• Step 1:
Disconnect the
battery earth lead.
• Step 2: Undo
the two clips
(arrowed
-
one at
each end of the
pipe) and remove
the compressed air
supply pipe, from
intercooler to inlet
manifold.
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